Spalling Repairs

Spalling Repair is an important part of our Structural repair knowledge and is a section that we have extensive training in. Below you will see some examples of spalling and what it could possibly look like in its later stages. Spalling is a threat to many buildings along the coastal regions and buildings that were not built to correct building standards or repaired according to internationally accepted building standards

What You Need to Know About Spalling

To protect your asset’s structural integrity and value, consider the following critical facts:

• Corrosion is the Root Cause: Spalling is the symptom; the underlying problem is steel reinforcement (rebar) corrosion caused by moisture and chlorides (salts) penetrating the concrete.
• The Coastal and Urban Threat: Deterioration is significantly accelerated by two primary environmental factors:
  • Marine Exposure (Chlorides): Salt spray and humidity in coastal areas rapidly penetrate the concrete surface.
  • Air Pollution (Carbonation): Urban and industrial air pollution releases carbon dioxide and sulfur dioxide. These gases penetrate the concrete, reducing its natural protective alkalinity in a process called carbonation, leaving the steel vulnerable to rust.
• A Structural Threat: As the steel rusts, it expands up to seven times its original volume, generating immense internal pressure that forces the concrete to fracture and detach.
• Beyond Aesthetics: While visible cracks and flaking are unsightly, the true danger is the loss of load-bearing capacity and integrity in critical structural elements.
• The Expertise Requirement: Effective repair involves accurately diagnosing the full extent of corrosion and carbonation, treating the exposed steel, and applying specialized mortars and coatings to halt the chemical process permanently.
• Standard Compliance: All remedial work must adhere to internationally accepted building standards to ensure the longevity and durability of the structural repair.